Automotive vehicle seat insert

ABSTRACT

There is disclosed a sealed edge insert suitable for placement within a seat of an automotive vehicle. The insert includes multiple layers, one of which includes a heater for providing an occupant of the seat with warmth. The insert also includes an air mover (e.g., a fan) for providing ventilation to the seat occupant. Further, the insert includes an extension that extends to a backside of a cushion component of the seat for attachment to provide fluid communication from the insert to the air mover.

CLAIM OF PRIORITY

The present application claims the benefit of U.S. provisionalapplication No. 60/512,230, filed on Oct. 17, 2003.

FIELD OF THE INVENTION

The present invention relates to a sealed insert for providing heating,ventilation or a combination thereof to a seat of an automotive vehicle.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning seats for automotive vehicles that provide added comfort tooccupants in the seats. Various innovations in providing seating comfortare discussed in U.S. Pat. Nos. 6,064,037; 5,921,314; 5,403,065;6,048,024 and 6,003,950, all of which are expressly incorporated hereinby reference for all purposes. In addition, other innovations inproviding seating comfort are discussed in U.S. patent application Ser.No. 09/619,171, filed Jul. 19, 2000, titled “Ventilated Seat Having aPad Assembly and a Distribution Device”; U.S. patent application Ser.No. 09/755,505, filed Jan. 5, 2001, titled “Ventilated Seat”; and U.S.patent application Ser. No. 09/755,506, filed Jan. 5, 2001, titled“Portable Ventilated Seat”, each of which are expressly incorporatedherein by reference for all purposes. In the interest of continuing suchinnovation, the present invention provides an improved sealed insert foran automotive vehicle seat for assisting in providing comfort control toan occupant in the seat.

SUMMARY OF THE INVENTION

According to the present invention, there is disclosed a sealed insertfor providing heating and ventilation to an automotive vehicle seat. Theinsert includes a middle layer sandwiched and between a forward layerand a rearward layer and sealed about a peripheral edge. The forwardlayer, the rearward layer or both preferably include a first opening anda plurality of second openings. Moreover, the middle layer preferablydefines an open space in fluid communication with the first opening, theplurality of second openings or both.

According to one embodiment, the vehicle seat includes a seat cushioncomponent and a seat backrest component, at least one of which isventilated. Each ventilated component includes an air-permeable trimsurface at the occupant contact areas of the seat and a cushion. Theinsert is located beneath the trim surface of each ventilated componentand the insert includes an extension with the first opening definedtherein. The extension preferably extends through a forward and arearward surface of the cushion of the ventilated component and an airmover is attached to the extension of the insert in fluid communicationwith the open space of the insert. In one highly preferred embodiment,the insert includes a body portion from which the extension extends andthe extension is contoured as it extends away from the body portion. Inanother embodiment, the air mover is fastened to lumbar guide wires ofthe automotive vehicle seat

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claimsand drawings, of which the following is a brief description:

FIG. 1 is a blown up perspective view of a seat insert in accordancewith an exemplary aspect of the present invention;

FIG. 2 is a flow diagram for producing seat inserts in accordance withan exemplary aspect of the present invention;

FIG. 3 is a partially cut-away elevational view of the seat insert ofFIG. 1 after assembly of the insert;

FIG. 4 is a sectional view of the insert of FIGS. 1 and 3 taken alongline 4-4 in FIG. 3;

FIG. 5 is a perspective view of an exemplary fan suitable forapplication in the insert of the present invention; and

FIG. 6 is a sectional view of the insert attached in an exemplary mannerto a seat of an automotive vehicle according to the present invention.

FIG. 7 is a front perspective view of an exemplary insert beingassembled to an exemplary backrest component of a vehicle seat.

FIG. 8A is a rear cut away perspective view of the exemplary backrestcomponent of FIG. 7 with the exemplary insert assembled thereto.

FIG. 8B is a perspective view of an exemplary fastener, which isemployed for attaching an air mover assembly to a seat.

FIG. 9 is a top perspective view of another exemplary insert beingassembled to an exemplary partially cut away seat component of a vehicleseat.

FIG. 10 is a top perspective view of the exemplary insert of FIG. 9assembled to the exemplary seat component.

FIG. 11A is a bottom perspective view of the exemplary seat component ofFIG. 9 during assembly.

FIG. 11B is another bottom perspective view of the exemplary seatcomponent of FIG. 9 after assembly.

FIG. 12 is a rear perspective view of an exemplary fan assemblyaccording to the present invention.

FIG. 13 is a front perspective view of the exemplary fan assembly ofFIG. 12.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon providing an insert suitablefor placement within an automotive vehicle seat to provide heating,ventilation or a combination thereof to an occupant in the seat. Theinsert will typically include multiple (e.g., three) layers and each ofthe layers may include one or more sub-layers. The insert preferablyincludes an extension that extends to a backside of a seating component(e.g., a backrest or seat support component) of the seat. As an example,the extension may extend through a cushion of the seat to a backside ofthe cushion. The extension of the insert typically connects the insertto a fan for providing ventilation. Advantageously, the extension can beshaped to allow the fan to be attached to various parts such as a frameor lumbar guide wires of a vehicle seat. One exemplary insert that maybe employed in the present invention is disclosed in U.S. patentapplication Ser. No. 10/434,890, filed May 9, 2003, which is herebyincorporated by reference for all purposes.

Referring to FIGS. 1 and 3-5, there is illustrated an exemplary insert10 suitable for placement within a seat of an automotive vehicle. Theinsert 10 preferably includes a plurality of layers that may be separatebut are preferably attached to each other to form the insert. In theembodiment shown, the insert 10 includes a first or forward layer 14(e.g., the layer of the insert configured to be closest an occupant ofthe seat), a second or middle layer 16 and a third or rearward layer 20(e.g., the layer of the insert configured to be furthest from theoccupant of the seat).

It is preferred that one of the layers 14, 16, 20 includes a heater. Inthe embodiment depicted, the forward layer 14 includes a heatersub-layer 26, which is preferably laminated to a gas barrier sub-layer28 (e.g., a film, a textile or otherwise) although such film is notnecessarily required. Various different types of heaters are suitablefor incorporation into a car seat and it is contemplated that any ofsuch heaters may be incorporated into the insert 10 of the presentinvention. Such heaters typically incorporate flexible electricalheating elements that are preferably thin, flat, non-obtrusive or acombination thereof. As examples, a lay-wire heater, a carbon fiberheater, a positive thermal coefficient (PTC) heater, a thermoelectricheater or the like, which are typically supported with a backing (e.g.,a cloth or fabric type backing) may be used within the insert. In apreferred embodiment, the heater sub-layer 26 is a carbon fiber typeheater with a backing (e.g., a nonwoven layer). One exemplary preferredheater is sold under the tradename CARBOTEX® and commercially availablefrom W.E.T Automotive Systems, Inc. in Germany and/or FTG Fraser-TechnikGmbH, Schleizer Strasse 56-58, D-95028 Hot/Saale, Germany. An example ofsuch a heater is disclosed in U.S. Pat. No. 6,064,037, issued May 16,2000, herein expressly incorporated by reference for all purposes.

The barrier sub-layer 28 is typically formed of a plastic or polymericmaterial that softens or melts upon exposure to heat to assist thesub-layer 28 to adhere to one or more other layers or sub-layers.Alternatively, the barrier sub-layer 28 may be formed of fabrics, wovenmaterials (e.g, goretex or microfibers), nylon, closed pore foam orother materials. Preferably, the barrier sub-layer 28 is substantiallyimpermeable to fluids and particularly air such that the sub-layer 28can assist in forming an air barrier as will be described furtherherein. Dimensionally, for a film barrier sub-layer, it is preferablefor the film thickness to be about 0.1 mm to about 2.0 mm thick and morepreferably about 0.7 mm to about 1.0 mm thick. Of course, it iscontemplated that the film sub-layer 28 may have a variable thicknessand may be outside of the aforementioned ranges.

The first layer 14 also includes one or more buffer sub-layers, one ormore adhesives or adhesive sub-layers, one or more tape sub-layers, oneor more porous foam layers or a combination thereof. Adhesive may besupplied in layers, drops or in a variety of other configurations.Preferably, the buffer layer is at least partially formed of aninsulating material.

In the preferred embodiment depicted, the first layer 14 includes twoadhesive sub-layers 34, one strip of tape 36 and one buffer sub-layer38. The adhesive sub-layers 34 are preferably formed of a hot meltadhesive although not necessarily required.

According to an alternative embodiment, it is contemplated that thefirst layer 14 may also include an air-permeable layer (not shown)between the buffer sub-layer 38 and an occupant of the seat. Theair-permeable layer, which may be any one of a variety of air-permeablematerials (such as reticulated foam, for example) may be able to helpdistribute air under the occupant.

One of the layers 14, 16, 20, preferably the middle layer 16, includes aspacer sub-layer 48 formed of a spacer material. In the preferredembodiment depicted, the middle layer 16 includes only the spacersub-layer 48, however, it is contemplated that additional sub-layers(e.g., adhesive sub-layers) or other materials (e.g., adhesives) may beincorporated into the middle layer 16. The particular sub-layer 48 shownis formed of polymeric (e.g., polyester) strand material that isinterwoven to provide opposing honeycomb structures 56 (e.g., fabricpanels), which are interconnected by several additional polymeric strandmaterials to provide open space 58 between the structures 56 while stillproviding cushion and support. As an example, one preferred material issold under the tradename 3MESH® and is commercially available fromMüller Textil GmbH, Germany or Müller Textiles, Inc., Rhode Island, USA.

In another of the layers 14, 16, 20 of the insert 10, preferably therearward layer 20, there is included an outer protective or buffersub-layer and another barrier sub-layer. In the embodiment shown, oneintegrated sub-layer 62 provides the both the barrier sub-layer 66 andthe outer protective sub-layer 68 although they may be providedseparately. The barrier sub-layer 66 for the rearward layer 20 may bethe same or different than the barrier sub-layer 28 of the forward layer14.

Preferably, the protective sub-layer 68 is formed of a fleece material,however, various other materials may be used such as gauze, cloth,fabric or the like. It is also preferable for the rearward layer 20 toinclude an adhesive or adhesive sub-layer 70 similar to or the same asthose discussed in relation to the forward layer 14. According to apreferred embodiment, the adhesive sub-layer 70 is provided integrallywith the integrated sub-layer 62.

In a highly preferred embodiment, an attachment component 72 is includedin one of the layers 14, 16, 20. The attachment component 72 shown inFIG. 1 is a frame member that preferably defines an opening orthrough-hole 74. It is contemplated that the frame member may be in avariety of configurations (e.g., annular, rectangular, square, geometricor otherwise) and may be formed of a variety of preferably rigid orsemi-rigid materials (metal, plastic or the like).

Notably, several of the materials of the various layers and sub-layersof the insert 10 may be environmentally friendly. For example, andwithout limitation, the materials of the spacer sub-layer 48, the bufferand protective sub-layers 38, 68 and the barrier sub-layers 28, 66 maybe recyclable.

Assembly

Generally, for forming a vehicle seat insert according to the presentinvention, it is contemplated that the various layers and sub-layers ofthe insert as described above may be combined in a variety of sequencesand according to a variety of protocols and technique as long as theinsert is or becomes sealed about its periphery. Thus, the order inwhich the various layers and sub-layers are combined and the techniquesof combining should not in any way limit the present invention unlesssuch order or techniques is specifically claimed. Moreover, it is alsocontemplated that there may be greater or fewer layers and that eachlayer may include greater or fewer sub-layers.

According to a preferred method, the sub-layers of the front or firstlayer and the third or rearward layer are each laminated separatelyfollowed by laminating the front layer to the rearward layer with themiddle layer in between. Referring to FIGS. 1 and 2, the first layer 14is formed according to a preferred method by feeding the varioussub-layers 38, 36, 34, 26, 28 to a laminator 80 (e.g., a belt and rollerlaminator).

The sub-layers 36, 38, 34, 26, 28 are preferably fed to the laminator 80from rolls or otherwise and are cut to shape to form the first layer 14after lamination. The first layer 14 may be cut to nearly any desiredshape or configuration. In the illustrated embodiment, the first layer14 is cut to be generally rectangular and to include an extension 84 anda plurality of through-holes 86. In FIG. 1, the through-holes 86 arearranged in a generally rectangular configuration and are eachsubstantially the same size. In FIG. 3, however, the through-holes 86are shown in a preferred configuration as progressively becoming largerfrom one side of the insert 10 to another.

Referring to FIG. 3, the through-holes 86 preferably increase in size asthe distance of the holes from the fan increases. This increase in sizecan provide a more uniform flow of air throughout the insert 10. It isbelieved that the increase in the total cross-sectional area ofthrough-holes 86 as the distance from the fan increases allows air toenter or exit the openings at a more uniform rate than if thecross-sectional areas of through-holes at different distances from thefan were equal.

The rearward layer 20, like the front layer 14, may be formed byattaching it sub-layers 62, 70 in a lamination process. Referring againto FIGS. 1 and 2, the barrier sub-layer 66, the protective sub-layer 68and the adhesive sub-layer 70 are fed to a laminator 90 (e.g., a beltlaminator) such that the barrier sub-layer 66 is between and attached tothe adhesive sub-layer 70 and the protective sub-layer 68. Thereafter,the rearward layer 20 is cut to have a shape substantially correspondingto the first layer 14. Of course, it is contemplated that the rearwardlayer may be cut into a variety of other configurations as well.Preferably, the rearward layer 20 includes a through-hole 98 as shown inFIG. 3 through an extension 100 of the rearward layer 20 thatcorresponds to the extension 84 of the first layer 14. It iscontemplated, however, that the through-hole 98 may also be formed inthe forward layer 14 if desired.

Once the middle layer 16 has been appropriately cut or otherwise shapedto the proper configuration, which preferably corresponds to the forwardand rearward layers 14, 20, each of the layers 14, 16, 20 are laminatedtogether to attach the layers 14,16, 20 to each other. As shown, themiddle layer 16 may be cut to include an extension 96 corresponding tothe extensions 84, 100.

In the preferred embodiment, the layers 14, 16, 20 are laminated in astationary lamination device 104 at elevated temperatures such that theadhesive sub-layer 70 of the rearward layer 20 and the outermostadhesive sub-layer 34 of the forward layer 14 both adhere and attach theforward layer 14 and the rearward layer 20 to the middle layer 16 (e.g.,the honeycomb structure). At the same time, the barrier sub-layer 28 ofthe front layer 14 and the barrier sub-layer 66 of the rearward layer 20are adhered to one another about an outer peripheral strip 106 of theinsert 10. For desirably locating the strip 106 (i.e., closer to therearward layer, the forward layer or somewhere therebetween), it iscontemplated that the forward or rearward layers may be cut slightlylarger or smaller than each other or they may be the same size.

It is also preferred that the attachment component 72 be sandwiched andattached between at least portion of the rearward layer 20 and themiddle layer 16 although the attachment component may be otherwiseattached (e.g., retrofit, fastened, or the like). Advantageously, theadhesive sub-layers 34, 70 and the outer laminated peripheral strip 106separately and together assist in forming the insert 10 as a tightlyintegrated unit wherein the layers 14, 16, 20 are substantially immobilerelative to each other.

While pre-cutting the layers 14, 16, 20 followed by laminating theperipheral edges of at least two of the layers 14, 20 have beendiscussed, it is contemplated that cutting of the layers 14, 16, 20 andlaminating of the layers may be integrated into a single processingstep. For example, it is contemplated that supplies (e.g., rolls) ofeach of the layers 14, 16, 20 may be provided to a machine thatlaminates outer edges of each of the layers 14, 16, 20 together forforming the peripheral strip 106 as the supplies continuously orintermittently provide the layer 14, 16, 20 to the machine. Thus,inserts 10 may be formed by cutting the inserts 10 with the peripheralstrip 106 from the laminated layers 14, 16, 20 and such cutting may beperformed by the laminating machine or by another cutting machine ordevice. In such an embodiment, it is contemplated that the through-holesin the forward layer 14 and the through-hole in the rearward layer maybe formed prior to, during or after lamination forming the outerperipheral strip 106.

It is also contemplated that additional cutting or laminating steps mayalso be employed. For example, it is contemplated that the layers, thesub-layers or both may be partially cut or shaped prior to stationary orother lamination and further cut or shaped after such lamination.

During final assembly 110, the wire harness 40 is preferably insertedwithin the pocket formed by the tape 36 or otherwise attached to theinsert 10. Also, a fan, the housing 120 of which is shown in FIG. 5, ispreferably attached to the attachment component 72 of the insert 10. Inthe embodiment shown, the housing 120 include flanges 124 suitable forsnap-fitting the housing 120 to the attachment component 72. In thismanner, the fan can be attached to the rest of the insert 10 and can beplaced in fluid communication with the through-holes 86 of the firstlayer 14, the open space 58 of the middle layer 16 and the through-hole98 of the rearward layer 20. Advantageously, the attachment component 72and flanges 124 provide a unique and efficient method of attaching thefan to the insert 10. It is contemplated however, that various othermethods of attachment (e.g., fasteners, sewing, mating threadedattachments, quick connects or the like) may be used to attach the fanto the insert 10. It is also contemplated that the attachment component72 and the housing 120 and flanges 124 of the fan may be varied withinthe scope of the present invention.

For assembly of the insert 10 to a vehicle seat (not shown), the insert10 is preferably connected (e.g., sewn, adhered or otherwise attached)to a portion of the seat such as the cover (e.g., a perforated leathercover) or to a cushion (e.g., foam) of the seat. In one preferredembodiment, a seat cover may be configured to include a pocket forreceiving the insert 10. Alternatively, it is contemplated that hook andloop fasteners may be utilized to attach the insert 10 to portions(e.g., the cover or foam) of the seat. For example, a strip of hook andloop fastener may be attached (e.g., adhered) to the insert and anotherstrip of hook and loop fastener may be attached (e.g., adhered) to thefoam cushion within a trench. Thus, the strips can be fastened to eachother thereby attaching the insert to the cushion.

The insert 10 is preferably positioned in the seat such that the firstlayer 14 is closer to the outer seat cover relative to the rearwardlayer 20 although not necessarily required. It is also preferable for anextension 139 formed by the extensions 84, 96, 100 of the layers 14, 20to extend behind, in front of or through the cushion of the seat suchthat the fan may be attached to a portion of the frame of the vehicleseat. Of course, attachment of the insert to the fan and attachment ofthe fan to the seat or other portion of the vehicle may be accomplishedin any order.

Preferably, the extension 139 is a tubular structure for providing fluidcommunication between the open space of the spacer layer 48 and the fan.Additionally, the wire harness 40, the heater sub-layer 26, the fan or acombination thereof are preferably connected in signaling communicationwith a control unit 130 and/or each other. The control unit 130 may beseparate from or integrated into the vehicle.

Moreover, while the air movers are typically shown as being configuredfor connecting to the extension of the insert. It is also contemplatedthat an air mover may be otherwise located relative to the insert. Forexample, a fan might be attached to a main or body portion of the insertand the fan may be attached to the foam cushion of the seat. In such anembodiment, it would typically be desirable to provide fluidcommunication to the fan, for example, by providing an opening in thefoam cushion.

In one embodiment referring to FIGS. 3, 4 and 6, the insert 10 is formedwith one or more (e.g., three) through-holes 140 that extend through thelayers, sub-layers or both of the insert 10 such that the through-holes140 extend entirely or substantially entirely through the insert 10.Preferably, the insert 10 (e.g., the barrier layers 28, 66) have a seal141 about the through-holes 140 for substantially preventing directfluid communication between the through-holes 140 and the open space 58within the insert 10. In the embodiment depicted, the barrier sub-layers28, 66 are attached to each other during the lamination process to forma substantially air-tight seal 141 about the through-holes 140.

Advantageously, the through-holes 140 can assist in the assembly of theinsert 10 and/or a seat cover 142 to a seat 144 of an automotivevehicle. As shown, for each through-hole 140, a portion 148 (e.g., acushion layer, a felt layer, a leather layer, combinations thereof orthe like) of the seat cover 142 is extended through the through-hole 140and is attached to foam 154 of the seat 144. In the embodiment depicted,the portion 148 is attached to the foam 154 by wrapping or otherwiseattaching the portion 148 about a member 162 (e.g., a bar or wire) thatis attached to (e.g., at least partially imbedded within) the foam 154.Additionally, one or more loops 166 (e.g., metal loops) are integratedwith the portion 148 and are looped about the member 162 for assistingin attaching the portion 148 to the member 162.

It shall be appreciated that, in embodiments alternative to the onedepicted, a variety of materials or members such as wire, thread,stitches, fasteners, foam or the like may extend through thethrough-holes 140 in the insert 10 for assisting in the attachment ofthe seat cover 142, the insert 10 or both to the other components of theseat 144. Moreover the materials or members may be connected to the seatcover, the foam, the seat frame, other portions of the seat or vehicleor the like depending on the desired configuration. It is alsocontemplated that other attachment methods such as the use ofalternative fastening devices may be employed in addition to oralternative to the through-holes 140. For example, hook and loopfasteners, sewing, adhesives or other fastening devices or mechanismsmay be employed to locate the insert 10 relative to the seat cushion,the seat cover 142 or both.

Operation

In operation, the insert of the present invention can preferably provideheating, ventilation or a combination thereof to an occupant of a seathaving the insert. In particular, if heat is desired, electric currentcan be induced to travel through the heater sub-layer 26 by the controlunit 130 or otherwise such that the heater sub-layer 26 can provide heatto the occupant.

Alternatively, if ventilation is desired, the fan can be operated viathe control unit 130 or otherwise to pull air through the through-holes86 in the first layer 14 of the insert 10, through the open space 58 ofthe middle layer 48 of the insert 10 and through the through-hole 98 ofthe rearward layer 20. Such air preferably flows at least partially pastthe occupant of the seat and through the seat cover (e.g., a perforatedleather seat cover or cloth seat cover) thereby providing ventilation tothe occupant and providing convective heat transfer from the occupant tothe flowing air.

Although, it may be preferable for only the heater sub-layer 26 or theventilation system to be running at one time, it is contemplated thatboth may be operated simultaneously. Moreover, it is contemplated thatboth the heater sub-layer 26 and the ventilation system may be operatedat various levels (e.g., 2 or more levels of output) such as by having afan that can operate at different levels or by having various levels ofelectricity flowing through or throughout the heater sub-layer 26. It isalso contemplated that the fan may push air into the open space 58 ofthe insert 10, such as during an initial short duration cool-down periodfor a vehicle interior (e.g., after the vehicle has been in sunlight orother hot conditions), as well as pulling air from the open space 58thereafter.

It is also contemplated that one or more temperature sensors (e.g., athermostat, a thermistor or the like) may be included adjacent theinsert, the trim layer or the like. Preferably, any temperature sensorsare near the seat cover or the insert for sensing a temperature closelyrelated to (e.g., at or near) a temperature being experienced by anindividual in the seat. Such temperature sensors may be in signalingcommunication with the control unit 130 such that the control unit 130can control the fan 22, the heater layer 28 or both for attaining ormaintaining a desired temperature at areas adjacent the individualand/or the temperature sensor. Moreover, the control unit 130 may beprogrammed with instructions for commanding the fan 22, the heater layer28 or both to change output levels (e.g., turn on or turn off) if thetemperature sensor senses a temperature above or below one or morethreshold levels. An example of such programming is described in acopending patent application titled “AUTOMOTIVE VEHICLE SEATING COMFORTSYSTEM”, Ser. No. 60/428,003, filed Nov. 21, 2002 and incorporatedherein by reference for all purposes.

Advantageously, the plastic film sub-layers 28, 66 respectively of thefirst and third layers 14, 20 provide a substantially gas-tight sealabout the middle layer 16 (e.g., the spacer sub-layer 48). In thismanner, gas flow relative to the open space 58 of the spacer sub-layer48 is substantially restricted to flowing through the through-holes 86,98 of the first and third layers 14, 20.

In alternative embodiments, the extension of the insert may extendbehind the seat cushion by extending around the seat cushion, extendingbetween two seat cushions, extending through a portion or the entiretyof the seat cushion, a combination thereof or the like. Moreover, it iscontemplated that the extension may be shaped as desired to assist theextension in extending to a desired location behind the seat cushion.For example, the extension may be arced, angled, contoured, straight orotherwise configured as it extends away from the rest of the insert.

Referring to FIGS. 7 and 8A, there is illustrated the insert 10 of thepresent invention assembled to a seat backrest component 200. In theparticular embodiment, a body portion 202 of the insert 10 overlays aforward surface 204 of a backrest cushion 206 of the backrest component200. Preferably, the body portion 202 of the insert 10 is attached tothe cushion 206 of the backrest component 200, although it mayalternatively be attached to a cover layer or other portion of a seat.Of course, the insert 10 may be attached to the cushion 206 or coverlayer using any of the attachments disclosed herein.

As shown, the backrest cushion 206 has an opening 210 (e.g., a slot orthrough-hole) extending generally through the cushion 206 of thebackrest component 200. In particular, the opening 210 extends throughthe forward surface 204 and a rearward surface 212 of the cushion 206 ata central area of the cushion 206. Advantageously, the opening 210 issized to receive the extension 139 of the insert 10 and the extension139 extends into and through the opening 210 and behind the cushion 206to oppose at least a portion of the rearward surface 212 of the cushion206. In the embodiment shown, the extension 139 extends to an air mover216 (e.g., a blower or other fan), which is also located behind thecushion 206.

Referring to FIGS. 9-11B, there is illustrated an alternative insert 220according to the present invention. The insert 220 is configured in amanner similar to any of the inserts described herein, however, theinsert includes an extension 222 that is contoured (e.g., arced orangle) or non-linear as it extends away from a body portion 226 of theinsert 220 and the extension 222 extends from a different edge of thebody portion 226 of the insert 220 than shown in previous embodiments.In particular, the extension 222 extends from an edge 228 that isconfigured to be coextensive with or extending substantially parallel toa side edge 230 of a seat cushion 232 or seat cushion component 234 asshown. Moreover, the extension 222 extends outward from the body portion226 of the insert 220 from a proximate portion 236 to a distal portion238 with a contoured (e.g., arced, angled or non-linear) portion 240therebetween. Preferably, the contoured portion 240 arcs to allow atleast the distal portion 238 of the extension 222 to substantiallycoextend or become substantially parallel with the edge 228.

As shown, the body portion 226 of the insert 220 overlays a forwardsurface 246 of the seat cushion 232 of the seat cushion component 234.Preferably, the body portion 226 of the insert 220 is attached to thecushion 232 of the seat cushion component 234, although it mayalternatively be attached to a cover layer or other portion of a seat.Of course, the insert 220 may be attached to the cushion 232 or coverlayer using any of the attachments disclosed herein.

As shown in cut-away, the seat cushion 232 has an opening 250 (e.g., aslotted through-hole) extending generally through the cushion 232 of theseat cushion component 234. In particular, the opening 250 extendsthrough the forward surface 246 and a rearward surface 254 of thecushion 232 at a side area of the cushion 232. Advantageously, theopening 250 is sized to receive the extension 222 of the insert 220 andthe extension 222 extends into and through the opening 250 and behindthe cushion 232 to oppose at least a portion of the rearward surface 250of the cushion 232.

In the embodiment shown, the extension 222 extends to an air mover(e.g., a blower or other fan), which is also located behind the cushion232. As an added advantage, the contoured portion 240 allows theextension 222 to extend toward a forward edge 254 of the seat cushion232 and/or seat cushion component 234. It should be understood, however,that such a contoured portion 240 may be configured to allow theextension 222 to extend toward any desired location.

It should be understood that in any of the embodiments disclosed herein,steps used to assemble the insert to a cushion component may be carriedout in any desired order. For example, the insert may be attached to thecushion component followed by extending the extension through thecushion opening. Alternatively, the extension may be extended throughthe cushion first.

Preferably, the air mover is attached to a component that maintains asubstantially identical location with respect to a seat or backrestcushion to which the insert is applied particularly during adjustment ofthe cushion position or seat. Of course, it is contemplated that thelocation of the air mover may change relative to the seat or backrestcushion as well.

Referring to FIGS. 12 and 13, there is illustrated one exemplary fanassembly 300 according to the present invention. The assembly 300includes the fan 216 attached to a mounting structure 304. In theparticular embodiment shown, the fan 216 includes a housing 308 (e.g., aplastic housing) that is attached to the mounting structure 304 with aplurality of fasteners 312 (e.g, screws). The mounting structure 304 isshown as a substantially rectangular metal plate with rounded offcorners 314 and a plurality of openings 318 (e.g., through-holes)extending through the plate, one opening 318, adjacent each corner 314.Of course, it is contemplated that a variety of structures other thanplates may be employed as the mounting structure and a variety ofmaterials (e.g., plastics, fabrics or the like) may be employed forforming the structure in a variety of alternative configurations.

The assembly 300, as shown in FIG. 8A also includes one or morefasteners 324 attached thereto. As shown in FIG. 8B, each fastener 324includes a body portion 326 with projections 328, 330 extendingtherefrom for interference fitting the fastener 324 to the mountingstructure 304. In the embodiment shown, each fastener 324 includes apair of projections 330 extending from an end 336 of the fastener 324and a conical projection 328. Preferably the pair of projections 330 andthe conical projection 328 extend at least partially toward each other,although not required.

Each fastener 324 also includes a fastening mechanism 340 for attachingthe fastener 324, the fan assembly 300 or both to one or more componentsof the seat or other portion of the automotive vehicle. Preferably, thefastening mechanism 340 can be attached by interference fit, adhesion,magnetism or otherwise. In the particular embodiment depicted, thefastening mechanism 340 is a C-shaped clip configured for forming aninterference fit. It is generally contemplated that the fasteningmechanism may be fitted with a locking mechanism (not shown) to enhancethe ability of the fastening mechanism 340 in attaching to members.

In FIG. 8A the fan assembly 300 is attached to a pair of members 350that extend substantially parallel to the back surface 212 of thebackrest component 200. As shown, the members 350 extend substantiallyvertically when the backrest component 200 is in the upright position,although they may extend in a variety of directions depending upon themembers 350 employed and the seat configuration. In the particularembodiment illustrated, the members 350 are cylindrical metal wires thatform a portion of a lumbar guide or back support adjustment assembly.Preferably, the members 350 are substantially stationary relative to thebackrest component 200, although not required.

For attaching the fan assembly 300 to the members 350, the end 336 andprojections 330 of the fasteners 324 are extended through the openings318 of the mounting structure 304 until the mounting structure 304 isinterference fit between the pair of projections 330 and the conicalprojection 328. Also, the fastening mechanisms 340 of each of fasteners324 are interference fit (e.g., at least partially clipped about) themembers 350.

As shown, the mounting structure 304 is between the members 350 and thecushion 206. In an alternative embodiment, however, the mountingstructure 304 may be located on a side of the members 350 away from thecushion 206. In such an embodiment, the fasteners 324 would have to bereversed such that the fastening mechanisms 340 extend toward thecushion 206 and the fan 216 would be located at least partially betweenthe members 350. Advantageously, such an embodiment can provide forgreater space between the fan 216 and the cushion 206 for allowing airto flow to or from the fan 216 more easily.

Referring to FIGS. 11A-11B, the fan assembly 300 is attached to asupport frame 360 for the cushion 232. As depicted, the mountingstructure 304 is attached to the support frame 360 and an opening 364(e.g., a through hole) extending into the insert 220 is placed in fluidcommunication with the fan 216. It is contemplated, however, that thefan 216 may be directly attached to the support frame 360 and themounting structure 304 may be removed. Moreover, the support frame 360,particularly when molded of plastic, can be molded to specificallyreceive the fan 216 and assist in its attachment thereto.

While is contemplated that any of the inserts or extensions may beattached to the fan using the ring 72 of FIG. 5, it is also possible todesign a ring, which aids in the assembly of the insert to the fan. Asan example, there is a ring 370 illustrated in FIG. 13 having anextension 372 (e.g., a semi-circular extension) extending from the ring370 and a lip 376 located adjacent an interface of the ring 370 and theextension 372. As shown, the extension 372 extends away from the ring370 in the same plane as the ring 370 and the lip 376 extends from theextension 372 at least partially perpendicular to the plane of the ring370 and the extension 372. Thus, the lip 376 is configured for extendingoutwardly away from any insert into which the ring 370 is installed.

To assemble the ring 370 and the insert when attached to the ring 370 tothe fan 216, the lip 376 can be abuttingly engaged with the housing 308of the fan 216 adjacent an edge 380 of the housing 308. In turn, thering 370 is aligned with fasteners 384 of the fan 216 such that the ring370 may be snap-fit to an inner annular edge 386 of the fasteners 384 asdescribed previously with regard to the ring 72 of FIG. 5.

It should be recognized that various alternative attachments other thanthe rings described may be employed to attach the air movers to theinserts. For example, attachments such as twist locks, spring locks,tabs on a ring, tabs on the air mover housing, combinations thereof orthe like may be employed. It should be further recognized that the airmover, the snap ring or both can include protective equipment such asfingerguards (e.g., cross-bars) or the like.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1-15. (canceled)
 16. A ventilated seat for a vehicle, comprising: avehicle seat having a backrest component which is ventilated, thebackrest component having an air-permeable trim surface at the occupantcontact areas of the seat and a cushion, wherein the cushion comprisesat least one opening through the cushion; a lumbar support including oneor more wires that form a portion of a lumbar guide disposed within thebackrest component; an insert located between the trim surface and thecushion of the backrest component, wherein the insert comprises: i)forward barrier layer and a rearward barrier layer made of an airimpermeable material, wherein the forward barrier comprises a pluralityof ventilation holes and the rearward barrier comprises at least oneport; and ii) a spacer material located between the barrier layers anddefining an open space that permits fluid communication between thecushion and the trim surface of the ventilated component, wherein thespacer material is less than coextensive with the barrier layers; and afan in fluid communication with the open space of the insert through theopening in the cushion, wherein the fan is attached to the one or morewires that form a portion of the lumbar guide; wherein the spacermaterial is a polymeric strand material.
 17. The ventilated seat ofclaim 16 wherein the insert is substantially coextensive with thecushion.
 18. The ventilated seat of claim 16 wherein the insert is lessthan coextensive with the cushion.
 19. The ventilated seat of claim 18wherein the barrier layers are sealed together using heat to soften ormelt the barrier layers.
 20. The ventilated seat of claim 18 wherein thebarrier layers are sealed together with an adhesive.
 21. The ventilatedseat of claim 16 wherein the fan both blows air toward the seat occupantor draws air away from the seat occupant.
 22. The ventilated seat ofclaim 16 wherein the fan includes a c-shaped clip configured for formingan interference fit to the one or more wires that form the portion ofthe lumbar guide.
 23. The ventilated seat of claim 16 wherein the insertfurther comprises a heater sub layer integrated therein.
 24. Aventilated seat for a vehicle, comprising: a vehicle seat having abackrest component which is ventilated, the backrest component having anair-permeable trim surface at the occupant contact areas of the seat anda cushion, wherein the cushion comprises at least one opening throughthe cushion; an insert located between the trim surface and the cushionof each ventilated component, wherein the insert comprises: i) forwardbarrier layer and a rearward barrier layer made of an air impermeablematerial where the barrier layers are open along a peripheral edge,wherein the forward barrier comprises a plurality of ventilation holesand the rearward barrier comprises at least one port; ii) a spacermaterial located between the barrier layers and defining an open spacethat permits fluid communication between the cushion and the trimsurface of the ventilated component, wherein the spacer material is lessthan coextensive with the barrier layers and includes a polymeric strandmaterial that is interwoven to provide opposing honeycomb structures;and iii) a heater, supported with a backing, integrated into the insert;and a fan in fluid communication with the open space of the insertthrough the opening In the cushion, wherein the fan is attached to oneor more wires that form a portion of a lumbar guide.
 25. The ventilatedseat of claim 24 wherein the fan includes a c-shaped clip configured forforming an interference fit to the one or more wires that form theportion of the lumbar guide.
 26. The ventilated seat of claim 24,including at least one temperature sensor disposed near the trim surfaceor the insert for sensing a temperature closely related to thetemperature being experienced by an individual in the seat.
 27. Aventilated seat, comprising: a seat having a seat component and abackrest component, at least one of which is ventilated, each ventilatedcomponent having an air-permeable trim surface at the occupant contactareas of the seat and a cushion, wherein the cushion comprises aplurality of openings through the cushion; an insert located between thetrim surface and the cushion of each ventilated component, the Insertcomprising an integrated heater, a topside barrier layer, an undersidebarrier layer and a spacer material comprising a polymeric strandmaterial that defines an open space that provides fluid communicationbetween a first opening in the underside barrier layer and a pluralityof second openings in the topside barrier layer of the insert; and anair mover in fluid communication with the open space of the insertthrough the plurality of openings in the cushion wherein the air moveris attached to a mounting structure.
 28. The ventilated seat of claim 27wherein the insert is sealed on at least one of its sides.
 29. Theventilated seat of claim 28 wherein the seat further comprises atemperature sensor in signaling communication with a control unit. 30.The ventilated seat of claim 29 wherein the control unit controls theair mover, the integrated heater or both to attain or maintain a desiredtemperature at areas adjacent the seat occupant or the temperaturesensor.
 31. The ventilated seat of claim 27 wherein barrier layers areattached to each other using an adhesive or welding.
 32. The ventilatedseat of claim 27 wherein the integrated heater comprises a flexibleelectrical heating element.